U.S. patent application number 10/136104 was filed with the patent office on 2003-11-06 for modular headliner and inflatable curtain assembly.
This patent application is currently assigned to TRW Vehicle Safety Systems Inc.. Invention is credited to Braun, William P., Lancaster, George E., Pillsbury, Charles S. IV, Wallner, John P..
Application Number | 20030205887 10/136104 |
Document ID | / |
Family ID | 29215668 |
Filed Date | 2003-11-06 |
United States Patent
Application |
20030205887 |
Kind Code |
A1 |
Wallner, John P. ; et
al. |
November 6, 2003 |
Modular headliner and inflatable curtain assembly
Abstract
A modular headliner assembly (10) includes an inflatable vehicle
occupant protection device (14) adapted to inflate away from a roof
(18) of a vehicle (12) into a position between a side structure
(16) of the vehicle and a vehicle occupant. The modular headliner
assembly (10) also includes a headliner (36) for covering an
interior portion (38) of the roof (18) and at least one support
device (40) for supporting the inflatable vehicle occupant
protection device (14) and the headliner in the vehicle (12). The
support device (40) includes a bracket (42) having a portion (44)
connectable to the inflatable vehicle occupant protection device
(14), fastener (202) for connecting the headliner (36) to the
bracket, and a fastener (222) for connecting the bracket to the
vehicle (12).
Inventors: |
Wallner, John P.; (Rochester
Hills, MI) ; Pillsbury, Charles S. IV; (Rochester,
MI) ; Braun, William P.; (Romeo, MI) ;
Lancaster, George E.; (Washington, MI) |
Correspondence
Address: |
TAROLLI, SUNDHEIM, COVELL & TUMMINO L.L.P.
526 SUPERIOR AVENUE, SUITE 1111
CLEVEVLAND
OH
44114
US
|
Assignee: |
TRW Vehicle Safety Systems
Inc.
|
Family ID: |
29215668 |
Appl. No.: |
10/136104 |
Filed: |
May 1, 2002 |
Current U.S.
Class: |
280/730.2 |
Current CPC
Class: |
Y10T 403/13 20150115;
F16B 5/0685 20130101; Y10T 24/44 20150115; B60R 21/213 20130101;
B60R 2013/0293 20130101; Y10T 403/32532 20150115; Y10T 403/18
20150115; F16B 2200/40 20180801 |
Class at
Publication: |
280/730.2 |
International
Class: |
B60R 021/22 |
Claims
Having described the invention, the following is claimed:
1. Apparatus comprising: an inflatable vehicle occupant protection
device that is adapted to inflate away from a roof of a vehicle
into a position between a side structure of the vehicle and a
vehicle occupant; a headliner for covering an interior portion of
the vehicle roof; and at least one support device for supporting
said inflatable vehicle occupant protection device and said
headliner in the vehicle, said at least one support device
comprising: a bracket having a portion connectable to said
inflatable vehicle occupant protection device; first fastening
means for connecting said headliner to said bracket; and second
fastening means for connecting said bracket to the vehicle.
2. Apparatus as recited in claim 1, further comprising a fill tube
having a portion located in said inflatable vehicle occupant
protection device, said fill tube directing inflation fluid into
said inflatable vehicle occupant protection device to inflate said
inflatable vehicle occupant protection device, said portion of said
bracket being connectable to said fill tube and said inflatable
vehicle occupant protection device.
3. The apparatus recited in claim 2, further comprising an
inflation fluid source for providing said inflation fluid for
inflating said inflatable vehicle occupant protection device, said
fill tube directing said inflation fluid from said inflation fluid
source into said inflatable vehicle occupant protection device.
4. Apparatus as recited in claim 2, wherein said portion
connectable to said fill tube and said inflatable vehicle occupant
protection device comprises a clamp portion of said bracket, said
clamp portion extending around portions of said fill tube and said
inflatable vehicle occupant protection device and clamping onto
said fill tube and said inflatable vehicle occupant protection
device.
5. Apparatus as recited in claim 4, wherein said bracket further
comprises a flange portion extending from said clamp portion, said
flange portion receiving said second fastening means.
6. Apparatus as recited in claim 5, wherein said bracket comprises
a single piece of metal material, said clamp portion comprising a
portion of said metal material plastically deformed around said
fill tube and said inflatable vehicle occupant protection device to
clamp onto said fill tube and said inflatable vehicle occupant
protection device.
7. Apparatus as recited in claim 6, wherein said portion of said
metal material plastically deformed around said fill tube and said
inflatable vehicle occupant protection device comprises a portion
of said metal material bent around said fill tube and said
inflatable vehicle occupant protection device.
8. Apparatus as recited in claim 1, further comprising a housing
for enclosing said inflatable vehicle occupant protection device in
a stored position, said at least one support device being
connectable to said housing.
9. Apparatus as recited in claim 8, wherein said bracket extends
through said housing to help connect said at least one support
device to said housing.
10. Apparatus as recited in claim 8, further comprising a fill tube
having a portion located in said inflatable vehicle occupant
protection device, said fill tube directing inflation fluid into
said inflatable vehicle occupant protection device to inflate said
inflatable vehicle occupant protection device, said portion of said
bracket being connectable to said fill tube and said inflatable
vehicle occupant protection device, said portion of said fill tube
being enclosed in said housing.
11. Apparatus as defined in claim 1, wherein said inflatable
vehicle occupant protection device has a generally elongated
configuration extending along the side structure of the vehicle
near the intersection of the side structure and the vehicle roof,
said headliner having a longitudinal edge extending along the side
structure of the vehicle near the intersection of the side
structure and the vehicle roof, said at least one support device
connecting said inflatable vehicle occupant protection device to
said headliner along said longitudinal edge.
12. Apparatus as recited in claim 11, wherein said at least one
support device comprises a plurality of support devices spaced
along said inflatable vehicle occupant protection device, said
plurality of support devices connecting said inflatable vehicle
occupant protection device to said headliner along said
longitudinal edge.
13. Apparatus as recited in claim 1, wherein said second fastening
means connects said bracket to the side structure of the
vehicle.
14. Apparatus as recited in claim 1, wherein said second fastening
means connects said bracket to a pillar of the vehicle.
15. Apparatus as recited in claim 14, wherein said pillar is one of
an A pillar, B pillar and C pillar of the vehicle.
16. Apparatus as recited in claim 1, wherein said second fastening
means comprises a threaded fastener.
17. Apparatus as recited in claim 1, wherein said first fastening
means is a fir tree fastener.
18. Apparatus for supporting an inflatable curtain module and a
headliner in a vehicle, the inflatable curtain module including an
inflatable curtain and a fill tube having a portion located in said
inflatable curtain, said apparatus comprising: a bracket having a
first portion extending around a portion of said inflatable curtain
and said fill tube and clamping onto said inflatable curtain and
said fill tube; first fastening means for connecting said headliner
to said bracket; and second fastening means for connecting said
bracket to the vehicle.
19. A modular vehicle headliner assembly comprising: a vehicle
headliner; an inflatable curtain module; and a bracket for
connecting said inflatable curtain module to said headliner, said
bracket being connectable to the vehicle to connect said headliner
and said inflatable curtain module to the vehicle.
20. The modular vehicle headliner assembly recited in claim 19,
wherein said inflatable curtain module comprises: an inflatable
curtain; a fill tube having a portion position within said
inflatable curtain, said fill tube delivering inflation fluid into
said inflatable curtain to inflate said inflatable curtain; and a
housing for enclosing said inflatable curtain and said fill tube in
a stored and deflated condition.
21. Apparatus comprising: a vehicle headliner having a first
longitudinal edge extendable along an intersection of a first side
structure of a vehicle and a roof of the vehicle, said headliner
having a second longitudinal edge extendable along an intersection
of a second side structure of the vehicle, opposite the first side
structure, and the vehicle roof; a first inflatable curtain module;
at least one first bracket for connecting said first inflatable
curtain module to said headliner along said first longitudinal
edge; a second inflatable curtain module; and at least one second
bracket for connecting said second inflatable curtain module to
said headliner along said second longitudinal edge, said at least
one first bracket and said at least one second bracket being
connectable to the vehicle to connect said headliner, said first
inflatable curtain module, and said second inflatable curtain
module to the vehicle.
22. The apparatus recited in claim 21, wherein each of said first
and second inflatable curtain modules comprises: an inflatable
curtain; a fill tube having a portion position within said
inflatable curtain, said fill tube delivering inflation fluid into
said inflatable curtain to inflate said inflatable curtain; and a
housing for enclosing said inflatable curtain and said fill tube in
a stored and deflated condition.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a vehicle headliner and an
inflatable apparatus for helping to protect a vehicle occupant in
the event of a side impact to the vehicle and/or a vehicle
rollover.
BACKGROUND OF THE INVENTION
[0002] It is known to inflate an inflatable vehicle occupant
protection device to help protect a vehicle occupant in the event
of a vehicle collision. One particular type of inflatable vehicle
occupant protection device is an inflatable curtain that inflates
away from the roof of the vehicle downward inside the passenger
compartment between a vehicle occupant and the side structure of
the vehicle in the event of a side impact or rollover. Such known
inflatable curtains are typically stored in a housing that opens
upon inflation of the inflatable curtain. A known inflatable
curtain is inflated from a deflated condition by inflation fluid
directed from an inflator to the inflatable curtain.
[0003] The inflatable curtain is typically stored in a deflated
condition along the roof rail above the side windows of the
vehicle. The inflatable curtain is connected to the sheet metal of
the vehicle and then is covered with a vehicle trim piece, such as
a side trim panel. A headliner typically overlies an interior
surface of the vehicle roof and extends laterally across the
vehicle roof. The headliner may also help cover the inflatable
curtain.
SUMMARY OF THE INVENTION
[0004] The present invention relates to a modular headliner
assembly that includes an inflatable vehicle occupant protection
device adapted to inflate away from a roof of a vehicle into a
position between a side structure of the vehicle and a vehicle
occupant. The modular headliner assembly also includes a headliner
for covering an interior portion of the roof and at least one
support device for supporting the inflatable vehicle occupant
protection device and the headliner in the vehicle. The support
device includes a bracket having a portion connectable to the
inflatable vehicle occupant protection device, fastener for
connecting the headliner to the bracket, and a fastener for
connecting the bracket to the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The foregoing and other features of the present invention
will become apparent to one skilled in the art to which the present
invention relates upon consideration of the following description
of the invention with reference to the accompanying drawings, in
which:
[0006] FIG. 1 is a schematic view of an apparatus including a
modular headliner and inflatable curtain assembly illustrating the
protection device in a deflated condition, according to the present
invention;
[0007] FIG. 2 is a schematic view of the apparatus of FIG. 1
illustrating the inflatable curtain in an inflated condition;
[0008] FIG. 3 is a perspective view of a portion of the apparatus
of FIG. 1;
[0009] FIGS. 4 and 5 are schematic views depicting the assembly of
a portion of the apparatus of FIG. 1;
[0010] FIG. 6 is an exploded sectional view depicting the assembly
of the apparatus of FIG. 1;
[0011] FIG. 7 is a sectional view of the apparatus taken generally
along line 7-7 in FIG. 1;
[0012] FIG. 8 is a sectional view of the apparatus taken generally
along line 8-8 in FIG. 2; and
[0013] FIG. 9 is a schematic perspective view of the apparatus of
FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0014] As representative of the present invention, an apparatus
including a modular headliner and inflatable curtain assembly
(hereinafter referred to as a modular headliner assembly 10) is
schematically depicted in FIGS. 1 and 2. The modular headliner
assembly 10 includes a vehicle headliner 36 connected to an
inflatable curtain module 28 by at least one support device 40. The
support devices 40 also connect the modular headliner assembly 10
to the vehicle 12. The inflatable curtain module 28 includes an
inflatable vehicle occupant protection device in the form of an
inflatable curtain 14 and a fill tube 22 for directing inflation
fluid from an inflator 24 into the inflatable curtain. The
inflatable curtain module 28 may also include a housing 26 (FIG. 1)
that stores the inflatable curtain in a deflated condition along
with the fill tube 22.
[0015] The side structure 16 of the vehicle 12 includes side
windows 20, an A pillar 30, a B pillar 32, and a C pillar 34. When
the modular headliner assembly 10 is installed in the vehicle 12,
the inflatable curtain module 28 extends along the vehicle roof 18
and along the side structure 16 of the vehicle 12 above the side
windows 20, and the headliner 36 overlies an interior surface 38 of
the roof 18.
[0016] The inflator 24 contains a stored quantity of pressurized
inflation fluid (not shown) in the form of a gas to inflate the
inflatable curtain 14. The inflator 24 alternatively could contain
a combination of pressurized inflation fluid and ignitable material
for heating the inflation fluid, or could be a pyrotechnic inflator
that uses the combustion of gas-generating material to generate
inflation fluid. As a further alternative, the inflator 24 could be
of any suitable type or construction for supplying a medium for
inflating the inflatable curtain 14.
[0017] Generally speaking, the inflatable curtain 14 may have any
construction suitable for helping to protect an occupant of a
vehicle in the event of a side impact to the vehicle or a vehicle
rollover. For example, the inflatable curtain 14 may comprise
fabric panels woven together as a single piece of material to
define inflatable chamber(s) of the curtain. Alternatively, the
inflatable curtain 14 may comprise separate panels, constructed of
fabric, elastomers, plastic films, or other suitable materials,
that are interconnected by means such as stitching, ultrasonic
welding, heat bonding, adhesives, etc. to define inflatable
chamber(s) of the curtain. The inflatable curtain 14 may have a
single layer construction or may have multiple layers of identical
or different materials. The inflatable curtain 14 may also be
coated with a gas impermeable material.
[0018] Each support device 40 includes a bracket 42, a fastening
device for connecting the headliner 36 to the bracket, and a
fastener for connecting the bracket to the vehicle 12. As
illustrated in FIGS. 3-5, each bracket 42 includes a clamp portion
44, a flange portion 46, and a headliner support portion 48.
Preferably, the bracket 42 is constructed of a single piece of
metal material that is cut in a predetermined pattern and folded or
bent to form the clamp portion 44, flange portion 46, and headliner
support portion 48. Those skilled in the art, however, will
recognize that alternative materials, such as plastic, may be used
to construct the bracket 42. It will also be recognized that the
configuration of the clamping portion 44, flange portion 46, and
the headliner support portion 48 of the bracket 42 may vary
depending on factors such as the structure of the headliner 36,
inflatable curtain module 28 and the vehicle 12.
[0019] The clamp portion 44 includes an arcuate portion 50 having
opposite first and second radial ends 52 and 54, respectively. A
flat portion 56 of the clamp portion 44 extends from the first
radial end 52 of the arcuate portion 50. When the bracket 42 is in
the closed position of FIGS. 3 and 5, the flat portion 56 extends
to adjacent the second radial end 54 of the arcuate portion 50. The
clamp portion 44 also includes an inner clamping surface 60.
[0020] The flange portion 46 extends from the second radial end 54
of the arcuate portion 50 in a direction perpendicular to the flat
portion 56 when the bracket 42 is in the closed position (FIGS. 3
and 5). The flange portion 46 is offset from the arcuate portion 50
by a shoulder portion 72. A clamping flange 74 extends from an end
of the flat portion 56 in a direction perpendicular to the flat
portion. When the bracket 42 is in the closed position of FIGS. 3
and 5, the clamping flange 74 is positioned in an adjacent,
generally parallel, overlying relationship with the flange portion
46. The flange portion 46 extends beyond the clamping flange 74 and
includes a housing support portion 102 and an angled mounting
portion 104. The mounting portion 104 includes a fastener receiving
aperture 106.
[0021] The headliner support portion 48 includes a rectangular
bottom wall 80 formed by the clamping flange 74. First and second
opposite side walls 82 and 84 and first and second opposing end
walls 86 and 88 extend perpendicularly from the bottom wall 80 to
form a chamber 100 of the bracket 42. The first side wall 82 is
defined by the flat portion 56 of the clamping portion 50. The
second side wall 84 extends perpendicularly from the clamping
flange 74 in a direction parallel to the first side wall 82. The
first and second end walls 86 and 88 consist of folded end portions
of the second side wall 84 that extend perpendicularly from the
second side wall to adjacent the first side wall 82.
[0022] First headliner support flanges 110 extend perpendicularly
from an edge of the second side wall 84 opposite the bottom wall 80
in a direction away from the chamber 100. A second headliner
support flange 112 extends perpendicularly from an edge of the
second side wall 84 opposite the bottom wall 80 in a direction
towards the first side wall 82. The second headliner support flange
112 includes a headliner fastener aperture 114.
[0023] Referring to FIGS. 3 and 4, the flange portion 46 includes a
pair of flange fastening apertures 62. The clamping flange 74 also
includes a pair of flange fastening aperture 64. As indicated by
the dashed lines in FIG. 3, the flange fastening apertures 62 and
64 are positioned in the chamber 100 in alignment with spaces on
opposite sides of the second headliner support flange 112. This
provides access into the chamber 100 and to the flange fastening
apertures 62 and 64 which, for example, may provide access to the
apertures for a device such as a tool.
[0024] Referring to FIGS. 2, 4, and 5, the inflatable curtain 14
includes clamp apertures 130 spaced along its length. Each clamp
aperture 130 extends entirely through the inflatable curtain 14. A
tightly stitched sew line 132 (FIGS. 4 and 5) completely encircles
each aperture 130. The sew line 132 helps to block leakage of the
inflation fluid from the inflatable curtain 14 when the inflatable
curtain is inflated.
[0025] The fill tube 22 is generally cylindrical in shape and
includes a series of clamp sections 140 spaced along its length.
The cylindrical fill tube 22 is flattened on one side along the
extent of each clamping section 140. Thus, the fill tube 22 has an
arcuate wall portion 142 and a flat wall portion 144 along the
length of each clamp section 140. Referring to FIGS. 1 and 2, the
clamp apertures 130 are spaced along the inflatable curtain 14 so
as to coincide with the spacing of the clamp sections 140 on the
fill tube 22. The clamp apertures 130 are thus positioned adjacent
the clamp sections 140 when the fill tube 22 is fully inserted into
the inflatable curtain 14.
[0026] The inflatable curtain module 28, i.e., the inflatable
curtain 14, fill tube 22, and housing 26, is assembled with the
support devices 40. Generally speaking, each support device 40 is
used in a similar or identical manner to assemble the inflatable
curtain module 28. Accordingly, assembly of the inflatable curtain
module 28 with one of the support devices 40 is described
herein.
[0027] The fill tube 22 is inserted into the inflatable curtain 14.
As illustrated in FIG. 4, in an opened condition of the bracket 42,
the clamping flange 74 is spaced apart from the flange portion 46.
The fill tube 22 and the inflatable curtain 14 are presented
towards the inner clamping surface 60 of the clamp portion 44 such
that the clamp section 140 of the fill tube is positioned within
the clamp portion. Once the fill tube 22 and inflatable curtain are
inserted into the clamp portion 44, as indicated by the dot-dash
line in FIG. 4, the flange portion 46 and the clamping flange 74
are moved together, thus placing the bracket 42 in the closed
position of FIG. 5.
[0028] When the bracket 42 is in the closed position with the
inflatable curtain 14 and the fill tube 22 in the clamp portion 44,
the arcuate portion 50 of the clamp portion 44 is positioned
adjacent the arcuate wall portion 142 of the clamp section 140. The
flat portion 56 of the clamp portion 44 is positioned adjacent the
flat wall portion 144 of the clamp section 140.
[0029] When the flange portion 46 and the clamping flange 74 are
moved together, they become positioned adjacent one another and the
flange fastening apertures 62 and 64 become aligned with each
other. A fastener 66, such as a rivet, may thus be installed to
extend through the apertures 62 and 64 to secure the flange portion
46 to the clamping flange 74. This helps to maintain the bracket 42
clamped onto the fill tube and the inflatable curtain 14.
Alternative means, such as spot welding or a mechanical clinch
connection, may also be used to secure the flange portion 46 to the
clamping flange 74. In this instance, the flange fastening
apertures 62 and 64 may not be necessary and may thus be
omitted.
[0030] When in the condition of FIG. 5, the first and second side
walls 82, 84, and the end walls 86, 88 extend through the aperture
130 in the inflatable curtain 14. The clamp portion 44 of the
bracket 42 encircles the fill tube 22 along the clamping section
140 of the fill tube 22. The portion of the inflatable curtain 14
(FIG. 4) surrounding the fill tube 22 is disposed between the inner
clamping surface 60 of the clamping portion 44 and the fill tube.
When closed around the fill tube 22 and the inflatable curtain 14,
the clamping portion 44 may undergo plastic deformation, which may
help to maintain the bracket 42 in the closed position. The inner
clamping surface 60 of the clamp portion 44 clamps onto the fill
tube 22 and the inflatable curtain 14. The fill tube 22, having a
cylindrical configuration on either side of the clamping section
140, helps prevent the support device 40 from sliding or otherwise
moving axially along the tube.
[0031] The housing 26 is preferably constructed of a single piece
of homogeneous plastic material formed, for example, by extrusion
or molding. Referring to FIGS. 68, the housing 26 includes an
arc-shaped end portion 160. An outer wall portion 162 extends from
a first terminal end 164 of the end portion 160. An inner wall
portion or closure flap 166 extends from a second terminal end 168
of the end portion 160, opposite the first terminal end 164.
[0032] A terminal longitudinal edge 170 of the outer wall portion
162 is interconnectable with a terminal longitudinal edge 172 of
the closure flap 166 by means such as interlocking beads 176. The
closure flap 166, when connected to the outer wall portion 162
(FIG. 7), at least partially encloses the inflatable curtain 14 in
a folded and stored condition in the housing 26 along with at least
a portion of the fill tube 22.
[0033] The outer wall portion 162, closure flap 166, and the beads
176 may extend substantially along the entire length of the housing
26. This may be the case, for example, if the housing 26 has an
extruded plastic construction. Those skilled in the art, however,
will recognize that certain ones of these elements may not extend
along the entire length of the housing 26. For example, the beads
176 may be located intermittently along the length of the housing
26. This may be the case, for example, if the housing 26 has a
molded plastic construction.
[0034] Portions of the outer wall portion 162 and closure flap 166
may be removed along the length of the housing 26 so that portions
of the support devices 40, particularly the brackets 42, can extend
through the housing 26. These housing portions may be cut away from
an extruded housing or molded integrally in a molded housing.
Referring to FIGS. 6-8, the outer wall 162 includes an opening 180
and the closure flap 166 includes an opening 182.
[0035] The housing 26 is positioned around the assemblage of the
brackets 42 clamped onto the inflatable curtain 14 and fill tube
22. The spacing of the openings 180 and 182 of the housing 26
coincides with the spacing of the clamp apertures 130 in the
inflatable curtain 14 and the clamping portions 140 of the fill
tube 22. The flange portion 46 of each bracket 42 extends through
the opening 180 in the outer wall portion 162 and is positioned
adjacent and overlying an outer surface of the outer wall portion.
The first headliner support flange 110 extends through the opening
182 in the closure flap 166 and is positioned adjacent and
overlying a portion of an outer surface of the closure flap. The
second headliner support flange 112 is positioned at least
partially in the opening 182 in the closure flap 166 such that the
headliner fastener aperture 114 is exposed in the opening.
[0036] The support device 40 also includes a fastener 202 for
connecting the headliner 36 to the headliner support portion 48 of
the bracket 42. As illustrated in FIGS. 68, the fastener 202 may
comprise a push-in "fir tree" type fastener. The fastener 202 is
constructed of a resilient material, such as plastic, and includes
a plurality of deflectable rims or prongs 204 extending radially
and at an acute angle from a shaft 206 of the fastener. The fir
tree fastener 202 also includes a head portion 208.
[0037] An opening 210 in the headliner 36 is aligned with the
opening 114 in the second headliner support flange 112. The fir
tree fastener 202 is pushed through the aligned openings 210 and
114 and into the chamber 100 to connect the headliner 36 to the
bracket 42. As the shaft 206 passes through the openings 210 and
114, the prongs 204 deflect towards the shaft, thus allowing the
fastener 202 to pass through the openings. Once through the
openings 210 and 114, the prongs 204 spring back towards their
normal resting position. If the fastener 202 is urged back out of
the openings 210 and 114, such as if the headliner 36 pulls on the
head portion 208, the prongs are deflected away from the shaft 206
and create an interference with the second headliner support flange
112. This helps prevent the fastener 202 from being pulled out of
the openings 210 and/or 114. The fir tree fastener 202 thus
connects the headliner 36 to the inflatable curtain module 28 to
form the modular headliner assembly 10.
[0038] The modular headliner assembly 10 may be installed in the
vehicle 12 as a single unit. This is best illustrated in FIG. 9. As
shown in FIG. 9, the modular headliner assembly 10 is positioned in
the vehicle 12 such that the headliner overlies an interior surface
38 of the vehicle roof 18. When installed, the headliner 36 has
first and second longitudinal edges 240 and 242 that extend
adjacent the intersection of the vehicle roof 18 and first and
second side structures 244 and 246 (i.e., driver side and passenger
side), respectively, of the vehicle 12. As shown in FIG. 9, the
support devices 40 are spaced to coincide with the A, B, and C
pillars 30, 32, and 34 of both the first and second side structures
244 and 246. This spacing could, however, be different. For
example, a support device 40 may be positioned along the
intersection of the side structure 16 and the roof 18 between the
vehicle pillars. The support devices 40 include fasteners 220 (see
also FIGS. 6-8), such as screws or bolts, that connect the support
devices to their respective vehicle pillars.
[0039] The connection of the modular headliner assembly 10 to the
vehicle is illustrated in detail in FIGS. 7 and 8. A vehicle roof
rail 250 is located at the intersection of the side structure 16 of
the vehicle and the vehicle roof 18. The side structure 16, roof 18
and roof rail 250 are formed from pieces of sheet metal that are
stamped or otherwise formed into predetermined shapes and welded or
otherwise connected to form a desired structure. In the embodiment
illustrated in FIGS. 7 and 8, inner and outer pieces of sheet metal
252 and 254, respectively, are used to form the side structure 16,
roof 18, roof rail 250, and B pillar 32 of the vehicle 12. Those
skilled in the art will appreciate, however, that the side
structure 16, roof 18, roof rail 250, and B pillar 32 may have
alternative constructions.
[0040] The fasteners 220 connect the flange portion 46 of the
bracket 42 to the side structure 16 of the vehicle 12 to connect
the modular headliner assembly 10 to the vehicle 12. More
specifically, each fastener 220 extends through the aperture 106 in
the mounting portion 104 of the flange portion 46 to connect the
bracket 42 to the vehicle 12. In the embodiment illustrated in FIG.
8, the fastener 220 is a screw that connects the bracket 42 to the
B pillar 32 of the vehicle 12.
[0041] When in the installed position of FIG. 7, the headliner 36
extends along the inner surface 38 of the roof 18 of the vehicle.
The headliner 36 has a portion 260 that extends at an acute angle
relative to the roof 18 adjacent the closure flap 166 of the
housing 26. The headliner 36 terminates at an edge 266 that is
positioned vertically above (as viewed in FIGS. 7 and 8) the
fastener 220 and the fastener aperture 106 on the mounting portion
104. As shown in FIGS. 7 and 9, this provides a clearance wherein
the mounting portions 104 are exposed, which helps facilitate
installation of the modular headliner assembly 10 in the vehicle
12.
[0042] A vehicle trim piece 262 overlaps the headliner 36 and has a
tab 264 that connects the trim piece to the headliner once the
modular headliner assembly 10 is installed in the vehicle 12. In
the embodiment illustrated in FIGS. 7 and 8, the trim piece 262
overlies the B pillar 32 of the vehicle 12. Similar trim pieces
(not shown) may also overlie the A pillar 30 (FIGS. 1 and 2) and C
pillar 34 of the vehicle 12. Also, other trim pieces (not shown)
may overlie portions of headliner between the vehicle pillars along
the vehicle side structure 16. The configuration of the vehicle
structure and the spatial and interconnecting relationships between
the vehicle structure, the modular headliner assembly 10, and trim
piece 262 at these locations may be similar to that illustrated in
FIG. 7.
[0043] The vehicle 12 includes a sensor mechanism 300 (shown
schematically in FIGS. 1 and 2) for sensing a side impact to the
vehicle 12 and/or a rollover of the vehicle 12. The sensor
mechanism 300 actuates the inflator 24 in response to the sensing
of a side impact or a vehicle rollover. In the event of a rollover
of the vehicle or a side impact to the vehicle 12 for which
inflation of the curtain 14 is desirable, the sensor mechanism 300
provides an electrical signal over lead wires 302 to the inflator
24. The electrical signal causes the inflator 24 to be actuated in
a known manner. The inflator 24 discharges fluid under pressure
through fill tube 22, which directs the fluid into the inflatable
curtain 14.
[0044] The inflatable curtain 14 inflates under the pressure of the
inflation fluid from the inflator 24. The beads 176 on the outer
wall portion 162 and the closure flap 166 separate under the
pressure of the inflation fluid, and the housing 26 opens. The
inflatable curtain 14 inflates away from the roof 18 in a downward
direction as shown in the drawings and in a downward direction with
respect to the direction of forward travel of the vehicle 12 into
the position illustrated in FIGS. 2 and 8.
[0045] When the housing 26 opens, the inflating curtain 14 causes
the closure flap 166 to move in a direction generally away from the
vehicle side structure 16 and roof rail 250 into the position
illustrated in FIG. 8. As the closure flap 166 moves from the
position of FIG. 7 to the position of FIG. 8, the closure flap
causes the portion 260 of the headliner 36 to move in a direction
generally away from the side structure 16 and roof rail 250 into
the position illustrated in FIG. 8. This creates a space between
the outer wall portion 162 and the closure flap 166, and between
the headliner 36 and trim piece 262, through which the inflatable
curtain 14 may extend during inflation and while in the inflated
condition.
[0046] The inflatable curtain 14, when inflated, extends along the
side structure 16 of the vehicle 12 and is positioned between the
side structure and any occupant of the vehicle. The inflatable
curtain 14 helps to protect a vehicle occupant in the event of a
vehicle rollover or a side impact to the vehicle 12. The inflatable
curtain 14, when inflated, helps to absorb the energy of impacts
with the curtain and helps to distribute the impact energy over a
large area of the curtain.
[0047] From the above description of the invention, those skilled
in the art will perceive improvements, changes and modifications.
For example, it will be appreciated that the configuration of the
vehicle structure and, thus, the spatial and interconnecting
relationships between parts such as the vehicle side structure 16,
roof 18, roof rail 250, trim pieces, and the components of the
modular headliner assembly 10 may vary depending upon the
particular vehicle. Therefore, it should be recognized that the
various structures shown in the illustrated embodiment and the
spatial and interconnecting relationships between those structures
is for illustrative purposes and may vary without departing from
the spirit of the present invention. Such improvements, changes and
modifications within the skill of the art are intended to be
covered by the appended claims.
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